Composite device having inductor and coupling member

ABSTRACT

A method of producing a composite component and a composite device which are small in size, high in the mass-production aptitude, and stable in the electrical characteristics. The composite component includes an inductor (1), coupling unit (3), and at least one circuit component (2) different from the inductor (1). The inductor (1) includes a coil support (12) having a coil winding portion (123) at the middle body thereof, and has a coil (11) wound around the coil winding portion (123). The coupling unit (3) is arranged such that one end of metal pieces (31 and 32) is fixed to one end face of the two end faces of the coil support (12) and the other ends of the metal pieces face each other across a space. The circuit component (2) is a chip component having electrodes (22 and 23) at two opposite ends of a base body (21), and is disposed between the metal pieces (31 and 32). The electrodes ( 22 and 23) are mounted fixedly to the metal pieces (31 and 32). A composite device is formed by combining the above-mentioned composite components with a housing. The composite component is produced by producing composite components and a housing on a lead frame, and then mounting the composite components in the housing.

TECHNICAL FIELD

The present invention relates to a composite component including aninductor, a composite device including at least one composite componentcombined with a housing, and a method of producing the composite device.

BACKGROUND ART

In producing an enductance-capacitance (LC) type composite componentmade up of a combination of an inductor and a capacitor for example, ora composite device including the composite component, a method generallyused hitherto is to mount a discrete inductor and a discrete capacitoron a circuit board so as to provide a composite component or device andcover the whole body with an insulating coating, or otherwise, to form acapacitor by patterning electrodes on a dielectric board and mount adiscrete inductor on this dielectric board so as to provide a compositecomponent or device and then cover the whole body with an insulatingcoating, as described in Japanese Patent Laid-open PublicationNo.58(1983)-15223.

As mentioned above, since the conventional LC type composite device isof such a structure in which a discrete capacitor and a discreteinductor are mounted on a circuit board or a discrete inductor ismounted on a dielectric board having a capacitor patterned therein, thesize of the device will become large in the plane direction and mountingwork will become difficult.

Also, in a conventional composite device of this kind, when a pluralityof inductors are mounted, the installed position or direction of theindividual inductors is liable to change, so that the electricalcharacteristics of the device may vary. Particularly when the inductorsare installed at small intervals to respond to the requirement ofdown-sizing of the device, a little positional change of the inductorssometimes causes a change in the electrical characteristics to anintolerable range.

Furthermore, since the conventional composite device of this kind is ofsuch a structure that the whole body is covered with an insulatingcoating, it is difficult to secure a high dimensional accuracy for theexternal shape. If a composite component includes an inductor, dependingon the way in which tile insulating coating is applied or filled, a coreof the inductor may change in the electrical characteristics affected bythe contraction stress of the insulating coating.

Therefore, it is an object of the present invention to provide acomposite component and a composite device which have solved theabove-mentioned conventional problems, which is reduced in size andsuitable for mass-production, and stable in the electricalcharacteristics.

Another object of the present invention is to provide a method ofproducing with high mass-production efficiency a composite device havingstable electrical characteristics, a small size, and an externalconfiguration with high dimensional accuracy.

DISCLOSURE OF INVENTION

In order to achieve the above object, the present invention provides acomposite component including an inductor, at least one circuitcomponent different from the inductor, and coupling unit for connectingthe inductor with the circuit component. The inductor has a coil supportand a coil. The coil support has two opposite end portions, and a coilwinding portion at the middle body thereof between the two opposite endportions. The coil is wound on the coil winding portion. The circuitcomponent is a chip component having electrodes at both opposite endportions of the coil support. The coupling unit includes at least onepair of metal pieces. A pair of metal pieces are arranged such that oneends of the metal pieces are fixed to one of the two end portions of thecoil support, and the other ends of the metal pieces face each otheracross a space. The circuit component is disposed between the metalpieces, and the electrodes are attached fixedly to the metal pieces.

As mentioned above, a pair of metal pieces forming the coupling unit forconnecting the inductor and the circuit component such as a capacitorhave one ends fixed to the end portion of the coil support and have theother ends facing each other across a space. The circuit component isdisposed between the metal pieces, and the electrodes are fixed to themetal pieces. Therefore, the circuit component to be combined with theinductor can be joined with the inductor at the top surface of theinductor without using a circuit board, and as a result, a compositecomponent small in size and with a smaller number of parts can beobtained.

The coil support as a component part of the inductor is in a bar or drumshape having two opposite ends and a coil winding portion at the middlebody between the two opposite ends. A circuit component is mounted to anend face of the coil support with a pair of metal pieces. Accordingly,the composite component can be reduced to a thin and small structure toan extent of thickness substantially determined by the length in theaxial direction of the coil support and the thickness of the circuitcomponent.

The coupling unit includes at least a pair of metal pieces. The metalpieces such as these can be formed by using a lead frame, and therefore,the inductor and the circuit component can be put together on the leadframe, so that a composite component with excellent mass-productionaptitude can be obtained.

The composite device according to the present invention has at least onecomposite component mentioned above and a housing. The housing has atleast one component holding socket which is open at one face of thehousing and in which the at least one composite component is inserted.Therefore, the position and the direction of the composite componentsare kept constant at all times by he component holding sockets. For thisreason, the electrical characteristics are less liable to change owingto a change of the position or the direction of the inductors, so thatsubstantially fixed, stable electrical characteristics can be secured.In assembling a composite device, it is only necessary to insertcomposite components into the component holding sockets of the housing,thus making the assembling work easy. Moreover, the external overallshape is standardized so that it is determined by the external shape ofthe housing, and as a result, a composite device with high dimensionalaccuracy can be obtained.

The producing method according to the present invention includes acomposite component producing process, a housing producing process, andan assembly process. In the composite component producing process,circuit components as a part of a composite component are mounted andsecured to the upside and downside of a lead frame, respectively, andthen, the lead frame is subdivided in the region including the circuitcomponents to thereby providing a discrete composite component. In thehousing producing process, a housing is molded on the lead frame. In theassembly process, at least one composite component is accommodated intothe housing.

Thus, in most producing processes, the lead frame is involved, whichnotably enhances the mass-production efficiency.

Furthermore, since in the housing the composite components are mounted,the composite components are positioned accurately. Therefore, acomposite device with stable electrical characteristics and astandardized external shape with high dimensional accuracy can beproduced.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view showing an embodiment of a compositecomponent according to the present invention;

FIG. 2 is a perspective view showing another embodiment of a compositecomponent according to the present invention;

FIG. 3 is a front sectional view of the composite component shown inFIGS. 1 and 2;

FIG. 4 is a front sectional view in another structural example of thecomposite device shown in FIGS. 1 and 2;

FIG. 5 is an exploded view in perspective showing an embodiment of acomposite device according to the present invention;

FIG. 6 is a sectional view of the composite device shown in FIG. 5;

FIG. 7 is a transparent perspective view of a housing of the compositedevice shown in FIGS. 5 and 6;

FIG. 8 is a perspective view of a lead frame used in a compositecomponent production process according to the present invention;

FIG. 9 is a perspective view showing a mounting process for mountingcircuit components to the lead frame shown in FIG. 8;

FIG. 10 is a perspective view of a composite component obtained throughthe processes of FIGS. 8 and 9;

FIG. 11 is a perspective view of a composite component after winding acoil on the composite component shown in FIG. 10;

FIG. 12 is a perspective view of a lead frame used in a housingproducing process according to the present invention;

FIG. 13 is a perspective view showing a forming process of the leadframe shown in FIG. 12;

FIG. 14 is a perspective view showing a molding process for molding ahousing to the lead frame shown in FIG. 13;

FIG. 15 is a perspective view showing a mounting process for mountingthe composite components to the housing obtained by the process of FIG.14; and

FIG. 16 is a final assembly process according to the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

The structure of a composite component according to the presentinvention will be described with reference to FIGS. 1, 2, 3, and 4. Inthose figures, reference numeral 1 denotes an inductor, 2 a circuitcomponent different from the inductor 1, and 3 coupling means forconnecting the inductor 1 and the circuit component 2.

The inductor 1 is substantially constituted by a coil 11 and a coilsupport 12. The coil support 12 has two opposite end portions 121 and122, and a coil winding portion 123 at the middle body thereof betweenboth end portions 121 and 122. A recessed portion 124 (shown in FIGS. 3and 4) is provided at least one end face (121) of both opposite ends 121and 122. The coil support 12 used in this embodiment is a core formed byferrite magnetic material and shaped like a drum having flanges at twoopposite end portions 121 and 122.

The circuit component 2 is a chip component having electrodes 22 and 23at both opposite end portions of a base body 21. The illustrated circuitcomponent is a capacitor having a plurality of internal electrodes 24and 25 (FIGS. 3 and 4) in the base body 21 formed by a dielectric. Thecircuit component 2 may be a resistor or other element different fromthe capacitor. One or more circuit components 2 may be provided. FIG. 1shows a case in which two circuit components 2 are provided, while FIG.2 shows a case in which only one circuit component 2 is provided.

The coupling means 3 contains at least a pair of metal pieces 31 and 32.In the case of FIG. 1, two pairs of metal pieces 31 and 32 are mountedto correspond to the two circuit components 2 provided, and in the caseof FIG. 2, a pair of metal pieces 31 and 32 are mounted to correspond tothe one circuit component 2 provided.

One end portions 312 and 322 of the pair of metal pieces 31 and 32 arefixed in the recessed part at the end portion 121 of the coil support12, and the other end portions 311 and 321 thereof are arranged to facewith each other across a space. In the embodiment shown in FIG. 3, therecessed part 124 is filled with an adhesive 33 so as to fix the metalpieces 31 and 32 in the recessed part 124. Besides this assembledstructure, it is possible to use a structure, as shown in FIG. 4, thatthe end portions 312 and 322 of the metal pieces 31 and 32 are buried inan insulating support 34, and this insulating support 34 is insertedinto and mounted to the recessed part 124 of the coil support 12.

The circuit component 2 is disposed between the end portions 311 and 321of the metal pieces 31 and 32, and the electrodes 22 and 23 thereof arerespectively fixed to the metal pieces 31 and 32 by means of soldering,for example. Therefore, the circuit component to be combined with theinductor 1 is Joined with the inductor 1 at the top of the inductorwithout using a circuit board or the like. Because of this structure, asmall-size composite component having a fewer number of parts can beobtained.

The coil support 12 which is a component part of the inductor 1 is in adrum shape having two opposite end portions 121 and 122 and also havinga coil winding portion 123 at the middle body thereof between the twoopposite end portions 121 and 122. To the end face of one end portion121 of the coil support 12, the circuit component 2 is attached by usingthe pair of metal pieces 31 and 32. Therefore, this composite componentcan be produced with a thin and small-size structure to an extent ofthickness substantially determined by the length of the axial directionof the coil support 12 and by the thickness of the circuit component 2.

The metal pieces 31 and 32 may be used as electrical terminalsconnecting the ends 111 and 112 of the coil 11. The ends 111 and 112 ofthe coil 11 may be wound around the metal pieces 31 and 32 to which theelectrodes 22 and 23 of the circuit component 2 are electricallyconnected. Exclusive-use metal pieces provided independently of thecircuit component 2 may be used for connection with the ends 111 and 112of the coil 11.

The composite component according to the present invention can be usedby mounting it as a discrete part on a circuit board, for example, orcan be used by enclosing it in a housing. When it is used as a discretepart, the side where the circuit component 2 exists is the side wherethe composite component is to be mounted, and the metal pieces 31 and 32can be used as terminals for mounting.

Referring to FIGS. 5 to 7, the composite device according to the presentinvention will be described. In FIGS. 5 to 7, reference numeral 4denotes the composite component, 5 a housing formed by an insulatingresin for example, and 6 a housing cover.

A plurality of the composite components 4, in this case three compositecomponents 4, are provided. The housing 5 has component holding sockets51 to 53 open to the atmosphere at one side face 50 of the housing 5,and their number corresponds to the quantity of the composite components4. The composite components 4 are accommodated respectively in thecomponent holding sockets 51 to 53. In the assembly process, only byinserting the composite components 4 into the respective componentholding sockets 51 to 53 of the housing 5, the composite components 4can be certainly positioned at specified positions. This makes theassembly work of the composite component very easy. In addition, thecomposite device has a standardized external shape determined by theexternal shape of the housing 5, so that it is possible to provide acomposite device with high dimensional accuracy.

Since the composite components 4 are inserted in the component holdingsockets 51 to 53, the position and the direction of these compositecomponents 4 are fixed by the component holding sockets 51 to 53 at alltimes. Consequently, the electrical characteristics are less liable tochange caused by a change in the position or the direction of theinductor 1, thereby securing substantially fixed stable characteristics.

The composite components 4 are mounted such that the coil support sidesthereof are located in the component holding sockets 51 to 53, and thatthe circuit components 2 are located outside the housing 5. By thisarrangement, it is possible to perform processes such as electrodetrimming or the like on the circuit components 2.

Terminals 54 and 55 are provided at suitable intervals on the thickportion of the housing S. Referring to FIGS. 6 and 7, it will beunderstood that the one end portions 541 and 551 of the respectiveterminals 54 and 55 are arranged so as to protrude from one face 50 ofthe housing 5. The other end portions 542 and 552 of the terminals 54and 55 are drawn out from the opposite face 56, that is, tile bottomface of the housing 5. The drawn-out end portions 542 and 552 are bentto have a face substantially flush with the face 56, and the endsthereof are bent to extend along the side face of the housing 5.

The portions of the terminals 54 and 55, which appear in the same faceas the bottom face 56 of the housing 5 are continuously connectedrespectively by connecting parts 543 and 553, but may be separatedaccording to a required circuit configuration. For example, theterminals 54 and 55 may be separated by providing slits at positions c(see FIG. 7) to be separated depending upon the circuit configuration.In the manner as described, wiring circuit patterns 71 and 72 by theterminals 54 and 55 can be formed.

Since the wiring patterns 71 and 72 appear on the bottom face 56, thewiring condition by the terminals 54 and 55 can be known by looking atthe bottom face 56 from outside. The wiring patterns 71 and 72 will bedifferent from each other in accordance with the type and the directionof the composite device. Therefore, the type of the composite device orthe direction thereof can be identified by looking at the wiringcondition as mentioned above, and thus wrong device insertion or wrongwiring can be prevented when the circuit is mounted. The patterns 71 and72 can be identified not only by the human eye but also by such as apattern recognition system. Thus, the composite devices can beclassified automatically in accordance with the type thereof andfurthermore can be arranged in a specified direction by using thepattern recognition system. Because the patterns 71 and 72 of theterminals 54 and 55 are formed in substantially the same plane with thebottom face 56, the installation stability is improved when thecomposite components are mounted.

As the lead frame material in the case that a housing 5 is formed bymolding on a lead frame having divided lead strips (terminals 54 and55), a phosphor bronze plate, for example, is suitable. For each of thecomposite component 4, one set of the terminals 54 and 55, each of whichterminals is constituted by two lead strips, are provided. Therefore,for the composite device, a plurality of sets of the terminals 54 and 55are provided.

The cover 6 for the housing 5 is formed by an insulating resin as wellas the housing 5 in this embodiment, and is mounted to the housing 5 soas to cover the face 50 thereof. Therefore, an insulating resin need notbe filled in the surrounding area of the composite components 4 insertedin the component holding sockets 51 to 53 of the housing 5. For thisreason, the electrical characteristics are not subject to change ordeterioration caused by the cure shrinkage stress of the insulatingresin. In order to couple the cover 6 with the housing 5, there areprovided projections 57 on the side faces of the housing 5, andindentations 61 in the cover at locations corresponding to projections57 of the housing. By an engaging and fixing mechanism such as theprojections 57 and the indentations 61, the cover 6 is fitted securelyon the housing 5.

The ends 311 and 321 of the metal pieces 31 and 32 of each compositecomponent 4 are set such that they protrude higher than the ends 541 and551 of the terminals 54 and 55 of the housing 5 when the compositecomponents 4 are accommodated in the housing 5. The end portions 111 and112 of the coil 11 are wound within the area of Δ h in the end portions311 and 321 of the metal pieces 31 and 32 (see FIG. 6). Thus, the woundportions of the end portions 111 and 112 of the coil 11 are preventedfrom being broken by abrasion with the terminals 54 and 55 when thecomposite components 4 are inserted into the component holding sockets51 to 53.

Referring to FIGS. 8 to 16, a method of producing a composite deviceaccording to the present invention will next be described. In thesefigures, FIGS. 8 to 11 show a composite component producing process,FIGS. 12 to 14 show a housing producing process, and FIGS. 15 and 16show a mounting process.

In FIG. 8, reference numerals 80 to 83 denote frame portions, 84 to 87first arm pieces, and 88 and 89 second arm pieces. Those metal piecesare formed by, for example, a press work on a long metal thin plate. Anexample of a metal thin plate is of phosphor bronze.

As the first arm pieces, it is necessary to provide at least a pair ofthose pieces. In the example of FIG. 8, there are two pairs of first armpieces 84 to 87. A pair of the first arm pieces 84 and 85 on one sideare located apart from each other. One ends of the first arm pieces 84and 85 are connected to the frame portion 82, and the other ends thereofrespectively have first bent pieces 841 and 851 and second bent pieces842 and 852. The first bent pieces 841 and 851 are bent in the samedirection with each other, and face to each other across a space. Thesecond bent pieces 842 and 852 are bent in the direction opposite to thedirection of the first bent pieces 841 and 851, and face to each otheracross a space. The other pair of first arm pieces 86 and 87 have firstbent pieces 861 and 871 and second bent pieces 862 and 872, structuredin the same manner as these of the above-mentioned pair of the first armpieces 84 and 85.

As the second arm pieces 88 and 89, at least one pair of those pieces isnecessary to be provided. One ends of the second arm pieces 88 and 89are connected to the frame portions 80 and 81. The other ends of thesecond arm pieces 88 and 89 are bent in the direction opposite to thedirection of the first bent pieces 841, 851, 861, and 871, face to eachother across a space, and have hook members 881 and 891 at their distalends. In another embodiment, the second arm pieces 88 and 89 may beformed at positions connected to the frame portions 82 and 83.

A circuit component 2 is inserted in the space between the first bentpieces 841 and 851 from the upside of the thus formed lead frame. Then,a coil support 12 of the inductor 1 is mounted from the undersideopposite the side of the lead frame where the circuit component 2 isfitted. On the mounting end surface of the coil support 12, there isprovided in advance a recessed part 124. In this recessed part 124, thesecond bent pieces 842, 852, 862, and 872 are inserted, and the coilsupport 12 is held by the hook members 881 and 891 provided at thedistal ends of the second arm pieces 88 and 89.

As mentioned above, since the circuit components 1 and 2 are mountedfrom both sides (upside and underside) of the lead frame, the assemblywork is made easy and it is possible to adopt an automatic assemblyprocess. The second bent pieces 842, 852, 862, and 872 are fixed, by forexample an adhesive in the recessed part 124, to the coil support 12.Simultaneously, the underside of the circuit component 2 is fixedtemporarily to the lead frame by an adhesive. Since the first arm pieces84 to 87 are continuously connected to the second bent pieces 842, 852,862, and 872, these first arm pieces 84 to 87 which also serve aselectrical lead terminals are used as positioning and fixing piecesalong with the second bent pieces 842, 852, 862 and 872. Namely, onelead frame performs two roles of lead terminal segments and thepositioning and fixing pieces, so that it is not necessary to provideexclusive-use lead terminal segments or positioning and fixing pieces.

After the coil support 12 for the Inductor 1 and the circuit component 2are mounted and fixed on the lead frame, the lead frame is cut atcutting positions X1 to X4 (see FIG. 9).

Consequently, a composite component A, shown in FIG. 10, which is madeby uniting the circuit components 1 and 2 through the first bent pieces841, 851, 861, and 871 (311 and 321) and the second bent pieces 842,852, 862, and 872 (312 and 322) of the first arm pieces 84 to 87,respectively, can be obtained.

Subsequently, by winding a coil 11 on the coil support 12 and performinga coil terminal treatment, a composite component as shown in FIG. 11 canbe obtained. The end portions 111 and 112 of the coil 11 are woundaround the end portions of the first bent pieces 311 and 321 (841, 851,861, and 871) electrically connected to the electrodes 22 and 23 of thecircuit component 2. Pieces of the first bent pieces 311 and 321 (841,851, 861 and 871) to which pieces the coil ends 111 and 112 arerespectively to be connected is determined by a required circuitconfiguration. Brazing or soldering the coil ends 111 and 112 to thefirst bent pieces 311 and 321 (841, 851, 861 and 871) may be carried outat this stage, but from tile viewpoint of improvement of workability andmass-production efficiency the brazing or soldering should preferably bedone in the process of mounting the composite components into thehousing as described later.

The housing producing process will next be described with reference toFIGS. 12 to 14. FIG. 12 shows a lead frame used in the housing producingprocess, FIG. 13 shows the forming process of a lead frame, and FIG. 14shows the molding process of the housing.

In FIG. 12, reference numerals 91 and 92 denote a pair of substantiallyparallel frame portions separated a certain distance, and 93 and 94denote lead terminal segments which are formed in a continuous metalthin plate. A typical example of usable metal thin plate is phosphorbronze.

The lead terminal segments 93 and 94 have first terminal portions 931and 941, connecting portions 932 and 942, and second terminal portions933 and 943, respectively. The illustrated lead terminal segments 93 and94 are provided on the frame portions 91 and 92.

There are a plurality of lead terminal segments 93 mutually spaced inthe longitudinal direction of the frame portion 91. One ends of thefirst terminal portions 931 are continuously connected to the inner endof the frame portion 91, and from these positions, the terminal portions931 extend in the direction of the frame portion 92. The other end ofthe terminal portions 931 are located at substantially intermediatepositions between the frame portions 91 and 92. One ends of theconnecting portions 932 are continuously connected to the other end ofthe first terminal portion 931. From these positions, the connectingportions 932 extend along the longitudinal direction of the frameportions 91 and 92. One ends of the second terminal portions 933 arecontinuously connected to the other ends of the respective connectingportions 932, and from these positions, the terminal portions 933 extendin the direction of the frame portion 91 while keeping a specified spacein relation to the first terminal portions 931. The other ends of theterminal portions 933 are free ends.

The lead terminal segment 94 is of the same structure as the leadterminal segment 93. More specifically, one ends of the first terminalportions 941 are continuously connected to the inner end of the frameportion 92, and from these positions, the terminal portions 941 extendin the direction of the frame portion 91. The other end of the terminalportions 941 are located at substantially intermediate positions betweenthe frame portions 91 and 92. One ends of the connecting portions 942are continuously connected to the other end of the first terminalportion 941. From these positions, the connecting portions 942 extendalong the longitudinal direction of the frame portions 91 and 92. Oneends of the second terminal portions 943 are continuously connected tothe other ends of the respective connecting portions 942, and from thesepositions, the terminal portions 943 extend in the direction of theframe portion 92 while keeping a specified space in relation to thefirst terminal portions 941. The other ends of the terminal portions 943are free ends.

As has been described, one end of each the first terminal portion 931(941) leads to the inner end of the frame portion 91 (92), and from thisposition, the first terminal portion 931 (941) is led in the directionof the frame portion 92 (91), and the other end thereof is locatedbetween the frame portions 91 and 92. Furthermore, each second terminalportion 933 (943) which leads to the first terminal portion 931 (941)through the connecting portion 932 (942) is led back In the direction ofthe frame portion 91 (92). Therefore, the distance between the leadterminal segment 93 and 94 can be reduced to the minimum valuesubstantially defined by a space between the first terminal portions 931and 941. For this reason, the housing can be reduced in size. Even whenthe lead terminal segments 93 and 94 are positioned so as to face witheach other between the frame portions 91 and 92, the distance betweenthe frame portions 91 and 92 has only to be selected considering the sumof the lengths of the first terminal portions 931 and 941, so that thelengths of the second terminal portions 933 and 943 need not beconsidered. Therefore, the size of the housing can be reducedremarkably.

Across the connecting portions 932 and 942, slits are provided at thepositions c where the lead frame is to be cut in accordance with arequired circuit configuration. The spaces between the respectiveadjacent terminal portions of the lead terminal segments 93 and 94 canbe arbitrarily determined depending upon the circuit configuration. Inmodified case, the terminal portions may be equally spaced.

As shown in FIG. 13, in the lead frame forming process, the secondterminal portions 933 and 943 are bent upright at appropriate positions,for example, at the junctions between these second terminal portions andthe connecting portions 932 and 942. As described above, one ends of theconnecting portions 932 and 942 are connected to the other ends of thefirst terminal portions 931 and 941, and from those positions ofJunction, the connecting portions 932 and 942 extend along thelongitudinal direction of the frame portions 91 and 92. Furthermore, theother ends of the connecting portions 932 and 942 are connected to theends on one side of the second terminal portions 933 and 943, while theother ends of the second terminal portions 933 and 943 are left as freeends. Therefore, the above-mentioned forming process can be performed.Even when the lead terminal segments 93 and 94 are provided so as toface with each other between the frame portions 91 and 92, the distancebetween these lead terminal segments is never changed by theabove-mentioned forming.

After the lead frame forming process, in the housing molding processshown in FIG. 14, a housing 5 of an adequate insulating resin is moldedon the lead frame. The housing 5 is formed in such a way as to formcomponent holding sockets 51 to 53 to accommodate one or more compositecomponents which have a structure shown in FIGS. 1 to 5 and are made bythe producing process shown in FIGS. 8 to 11.

The component holding sockets 51 to 53 are arranged to have an opening alittle larger than the external dimension of the coil support 12 as anintegral part of the inductor 1. In addition, the second terminalportions 933 and 943 of the lead terminal segments 93 and 94 aredesigned to protrude from the surface 50 of the housing 5. Further, thehousing 5 is molded such that the first terminal portions 931 and 941and the connecting portions 932 and 942 form a face substantially flushwith the bottom surface 56 of the housing 5.

By providing slits at the positions c (see FIG. 6) to be cut inaccordance with the required circuit configuration for the connectingportions 932 and 942 in order to subdivide the respective lead terminalsegments 93 and 94, the wiring patterns by the connecting portions 932and 942 can be formed. Since the connecting portions appear on thebottom surface 56 of the housing 5, the wiring conditions of the leadterminal segments 93 and 94 can be checked visually or mechanicallyaccording to the positions c of the slits when the bottom surface 56 isinspected from outside, and the type or the direction of the compositedevices can be thereby recognized, so that mounting errors can beavoided. Moreover, the lead terminal segments 93 and 94 constitute aface substantially in the same plane with the bottom surface 56, andtherefore, the installation stability in mounting composite componentscan be improved.

After the housing molding process, as shown in FIG. 15, compositecomponents A are inserted into the component holding sockets 51 to 53 ofthe housing 5, respectively.

When assembling a composite device, only by inserting compositecomponents A into the component holding sockets 51 to 53 of the housing5, the composite components A can be set at specified positions, so thatthe assembly work becomes very easy. What is more, the overall externalshape of the composite device will be standardized as it is determinedby the external shape of the housing 5, by which a composite device withhigh dimensional accuracy can be obtained. Moreover, since the compositecomponents A are inserted into the component holding sockets 51 to 53,the position and the direction of the composite components A are keptconstant by the component holding sockets 51 to 53 at all times, theelectrical characteristics are less liable to change by a change in theposition or the direction of the inductors, with the result that thestable and substantially fixed electrical characteristics can besecured.

The end portions 311 and 321 of the metal pieces 31 and 32 of acomposite component A are set so as to protrude higher than the secondterminal portions 933 and 943 of the lead terminal segments 93 and 94.Within the area of height difference between them, the end portions 111and 112 of the coil 11 are wound. By this arrangement, the woundportions of the terminal ends 111 and 112 of the coil 11 are preventedfrom being broken by abrasion with the lead terminal segments 93 and 94when the composite components a are inserted into the component holdingsockets 51 to 53.

After this, the wound coil end portions 111 and 112, the second terminalportions 933 and 943, the metal pieces 31 and 32, and the circuitcomponent 2 are soldered together simultaneously. By this soldering, thecomposite components A are fixed in the component holding sockets 51 to53.

Then, the first terminal portions 931 and 941 are cut at the cuttingpositions along the lines X5--X5 and X6--X6, and are subjected tonecessary processes, including the first terminal portions 931 and 941are bent along the side faces of the housing. Thus, a composite deviceshown in FIG. 16 is obtained.

As shown in FIG. 16, the housing cover 6 is attached to the housing 5 insuch a manner as to cover an opened side 50 of the housing 5. Therefore,the surrounding area around the composite components A inserted in thecomponent holding sockets 51 to 53 need not be filled with an insulatingresin or the like. For this reason, the electrical characteristics arenot subject to change or deterioration owing to the cure shrinkagestress or the like of the Insulating resin.

The advantages by the present invention described are summarized in thefollowing.

(a) a pair of metal pieces as coupling means for connecting the inductorand the capacitor are arranged such that one ends of the metal piecesare fixed to the end face of the coil support and the other ends thereofface with each other across a space. The circuit component is disposedbetween the metal pieces, and the electrodes are mounted fixedly to themetal pieces. Therefore, the circuit component to be combined with theinductor can be Joined with the inductor at the top of the inductorwithout using such as a circuit board. As a result, a compositecomponent in a reduced size with a fewer number of parts can beobtained.

(b) The coil support as a component part of the inductor is in a bar ordrum shape having two opposite end portions and a coil winding portionat the middle body thereof between the two opposite end portions. Havinga circuit component mounted at the one end portion thereof using a pairof metal pieces, the composite component can be produced in a thin andsmall structure to an extent of thickness substantially determined bythe length in the axial direction of the coil support and the thicknessof the circuit component.

(c) The coupling means includes at least a pair of metal pieces that canbe made from a lead frame. Therefore, by using such the lead frame, theinductor and the circuit component can be put together. As a result, acomposite component highly suitable for mass-production can be obtained.

(d) The housing has component holding sockets which open on one facethereof, and the composite components have their coil support sideswhich are inserted in the component holding sockets. Therefore, thecomposite components are kept in the constant position and direction atall times, and the electrical characteristics are least likely to changeby a change of the position and the direction of the inductor, so that acomposite device with the substantially fixed, stable electricalcharacteristics can be provided.

(e) In the assembling work, it is only necessary to insert compositecomponents in the component holding sockets of the housing, so that acomposite device assembled easily can be provided.

(f) The overall shape is a standardized shape determined by the externalconfiguration of the housing, which makes it possible to provide acomposite device with high dimensional accuracy.

(g) The production method according to the present invention comprises acomposite component producing process, a housing producing process, andan assembly process. The composite component producing process is a stepin which inductors and circuit components are mounted and fixed on theupside and the underside of a lead frame. Subsequently, the lead frameis cut in the region having the circuit components to thereby obtainseparate composite components. In the housing producing process, ahousing is molded on the lead frame, and in the assembly process, theabove-mentioned composite components are accommodated in the housing.Therefore, by this production method, stable electrical characteristicscan be obtained, and a composite device having an external shape withhigh dimensional accuracy can be produced with high mass-productionefficiency.

It is claimed:
 1. A composite component comprising:an inductor having acoil support and a coil, said coil support including two opposite endportions and a coil winding portion between said two opposite endportions, said coil being wound on said coil winding portion; a couplingmeans including at least one pair of metal pieces arranged such that oneend of said metal pieces is fixed to one of said two opposite endportions of said coil support and the other ends of said metal piecesface with each other across a space; and at least one circuit componentwhich is different from said inductor, said circuit component being achip component having electrodes at two opposite ends thereof and beingdisposed between said metal pieces, said electrodes being fixed to saidmetal pieces.
 2. A composite component as claimed in claim 1, whereinsaid coil support has a recessed portion at one end face thereof, andwherein said one ends of said metal pieces are fixed to said coilsupport at said recessed portion.
 3. A composite component as claimed inclaim 1, wherein said circuit component is a capacitor.
 4. A compositecomponent as claimed in claim 1, wherein only one of said circuitcomponent is provided.
 5. A composite component as claimed in claim 1,wherein two of said circuit components are provided.
 6. A compositecomponent as claimed in claim 1, wherein said coil support is a core. 7.A composite component as claimed in claim 6, wherein said core is madeof ferrite magnetic material.
 8. A composite device comprising:at leastone composite component which is provided with an inductor having a coilsupport and a coil, said coil support including two opposite endportions and a coil winding portion between said two opposite endportions, said coil being wound on said coil winding portion, a couplingmeans including at least one pair of metal pieces arranged such that oneend of said metal pieces is fixed to one of said two opposite endportions of said coil support and the other ends of said metal piecesface with each other across a space, and at least one circuit componentwhich is different from said inductor, said circuit component being achip component having electrodes at two opposite ends thereof and beingdisposed between said metal pieces, said electrodes being fixed to saidmetal pieces; and a housing having at least one component holding socketat one face thereof, in said at least one holding socket said at leastone composite component is mounted.
 9. A composite device as claimed inclaim 8, wherein said composite component has a coil support side towhich side one end portion of said coil support is fixed, and whereinsaid coil support side is inserted in said component holding socket. 10.A composite device as claimed in claim 8, wherein said device has aplurality of said composite components, and wherein said housing has aplurality of said component holding sockets as many as the number ofsaid composite components.
 11. A composite device as claimed in claim 8,wherein said housing has terminals protruding from said one facethereof, and wherein said metal pieces of said composite component faceto said terminals of said housing and are electrically connected to saidterminals on said one face of said housing.
 12. A composite device asclaimed in claim 11, wherein said composite component is inserted insaid component holding socket so that said other ends of said metalpieces protrude higher than ends of said terminals to provide a heightdifference between them, and wherein end portions of said coil areconnected to said metal pieces within an area of said height differenceexisting on said metal pieces.
 13. A composite device as claimed inclaim 11, wherein said terminals are provided for each of said componentholding sockets, are led from said one face to an opposite face of thehousing, are drawn out from said opposite face, and are bent to form aface substantially the same plane with said opposite face, a part of theterminals appearing on said opposite face forming a wiring pattern. 14.A composite device as claimed in claim 8, wherein said housing includesa housing cover which is attached to said housing so as to cover saidone face of said housing.